EP0313055A1 - Verbundmaterial und Verfahren - Google Patents

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Publication number
EP0313055A1
EP0313055A1 EP88117510A EP88117510A EP0313055A1 EP 0313055 A1 EP0313055 A1 EP 0313055A1 EP 88117510 A EP88117510 A EP 88117510A EP 88117510 A EP88117510 A EP 88117510A EP 0313055 A1 EP0313055 A1 EP 0313055A1
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EP
European Patent Office
Prior art keywords
percent
composition
range
weight
cement
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Application number
EP88117510A
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English (en)
French (fr)
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EP0313055B1 (de
Inventor
James P. Carlson
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Aerex International Corp
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Aerex International Corp
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Application filed by Aerex International Corp filed Critical Aerex International Corp
Priority to AT88117510T priority Critical patent/ATE77615T1/de
Publication of EP0313055A1 publication Critical patent/EP0313055A1/de
Application granted granted Critical
Publication of EP0313055B1 publication Critical patent/EP0313055B1/de
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/14—Minerals of vulcanic origin
    • C04B14/18—Perlite
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the invention relates to an improved composite material and a method for producing the composite mate­rial. More particularly, the improved composite material is useful in constructing buildings and other applications where concrete is used, but it is lighter and stronger than concrete.
  • Concrete is frequently used as a construction mate­rial.
  • concrete is cast on structural steel to insulate the structural steel from damage due to a fire. This is necessary because steel quickly loses tensile strength once it reaches temperatures of 1000°F.
  • Concrete is not a good insulator and reacts badly to thermal shock created by the extreme temperatures of a fire. This thermal shock may cause cracks throughout the concrete and spalling where large pieces of the concrete surface fall away from the installation.
  • Organic materials have been used to furnish fire protection for structural steel.
  • name brands of organic materials used for this purpose include Albi­clad, Chartek and Thermo-lag. These materials furnish protection through processes known as intumescense, ablation, and sublimation. These organic systems are expensive and typically fail on a high-rise fire test when the temperature of the test sample elevates rapidly, in five minutes, to 2000°F.
  • Concrete also suffers from the drawback of poor tensile strength when used as a building material.
  • Typical concrete materials have a tensile strength of approximately 300 pounds per square inch (psi) versus a compressive strength of approximately 3000 psi. Conse­quently, concrete is not generally used alone as a struc­tural material, and instead it must be supplemented by a high tensile strength material such as steel.
  • the perlite used as an additive in known concrete material consists of either commercially used perlite which has particle sizes greater than 30 mesh on the Tyler Standard Screen Scale or perlite fines which have particle sizes ranging from 8 to 200 mesh.
  • the commercially used perlite and perlite fines are expanded before they are used as an additive in known concrete materials.
  • the expansion process consists of rapidly heating the perlite particles with the result that they pop like popcorn.
  • the known perlite-added concrete materials tend to be soft and friable, with a hardness on the shore D scale in the range of 45 to 50. They also have a low compressive strength of 500 to 800 psi, and a low tensile strength of approximately 300 psi.
  • the strength characteristics of known perlite-added concrete materials have been improved by applying pressure to the wet mix of perlite, cement, and water before it dries into the final product (U.S. Patent No. 3,565,650).
  • the resulting perlite-added concrete material has a compressive strength of approximately 1200 psi and a tensile strength of approximately 700 psi.
  • Concrete and concrete derived materials are also used in prefabricated structural and decorative components of buildings.
  • concrete is typically used for face panels in prefabricated buildings because concrete can be cast into panels which have a selected texture.
  • concrete can be treated to leave an exposed aggregate surface.
  • the invention teaches an improved composition com­prising cement and perlite fines mixed in the range of 30 to 85 percent by weight of cement with the remainder made up of perlite fines.
  • the composition comprises cement and perlite powder in a ratio of about 1/2 by volume, respectively.
  • components may be added to the improved composition to achieve particular results.
  • components such as glass fibers, a plasticizer, an air entrainer, or a liquid binder can be added to modify the physical properties of the composite material.
  • Water is mixed with the improved composition to form a castable, moldable mixture that dries into an improved composite material.
  • the improved composite material has fireproofing and strength characteristics superior to ordinary concrete and may be used in its place.
  • Cement and perlite fines are dry mixed to form a uniform mixture comprising an improved composition. Water is then thoroughly mixed with the improved composition to form a moldable, castable material. This material, when dry, comprises the improved composite material.
  • the invention provides an improved composition comprising the following components: Component Percentage By Weight Cement 30 to 85 Perlite fines 70 to 15 100
  • the cement may be Portland Cement, Calcium Aluminate cement, or any other variety of compound generally known as a cement.
  • Perlite fines are any extremely fine perlite mate­rial. Particularly, perlite fines are perlite material with particle sizes less than 200 mesh. This contrasts with known perlite-added concrete materials that use perlite fines or commercially sold perlite with particle sizes greater than 200 mesh (U.S. Patent No. 3,565,650).
  • perlite fines that consist essentially of perlite powder are used.
  • Perlite powder is generated when perlite ore is exfoliated by being rapidly heated. The rapid heating causes the perlite ore particles to pop like popcorn. This process produces a very fine type of dust material, designated as perlite powder, that is entrained in the hot gases used in the process.
  • the perlite powder was at one time exhausted into the atmosphere with the hot gases. Enactment of environmental regulations has, however, necessitated that the perlite manufacturing industry eliminate this type of particulate emission. Bag houses, a filtration system for removing entrained particulates from gas streams, are typically used to remove the perlite powder. Commercial perlite manufacturing operations generate large quantities of perlite powder as a waste material from their bag houses.
  • a microscope has been used to conduct a particle size analysis on the perlite powder particles and most of the particles were measured in the range of 20-25 microns. This indicates that the majority of perlite powder par­ticles would pass through a 400 mesh screen which corre­sponds to 37 microns in the Tyler Standard Screen analysis system.
  • compositions of the invention may be added in selected quantities to the compositions of the invention to vary the properties of the resulting improved composite material or to facilitate the method of making the improved composite material.
  • an amount of aggregate such as sand may be added to facilitate the dry mixing of the cement and perlite fines to form the composition.
  • the addition of any material classified as an aggregate can substitute for the sand.
  • Glass fibers or a similar material may be added to provide secondary reinforcing for the improved composite material.
  • one-half inch glass fibers may be added to the composition.
  • additives can also be added to vary the prop­erties of the composition.
  • resin such as PVA resin can be added to strengthen and provide water resis­tance to the finished product.
  • organic plasticizing agents can be mixed with the dry elements to reduce the amount of water required to blend the final composition.
  • a plasticizing agent is Daracem-100 supplied by W.R. Grace.
  • an air entraining agent may be added to reduce the weight of the finished product.
  • An example of an air entraining agent is Airtite, supplied by Gifford Hill.
  • the composition is prepared by dry mixing the cement and perlite fines according to the desired percentages by weight or volume. This procedure can be performed in any large bin type mixer by tumbling. After the mixing is complete, the composition may be stored in standard size packages or in large quantities.
  • the cement and perlite fines combine to create a unique composition that is used to make the improved composite material. It is believed that after the cement and perlite fines are thoroughly mixed a chemical process occurs which prevents the identification of cement or perlite fines in the resulting improved composite material. It is also believed that the perlite fines retain sufficient moisture to cause the chemical process between the cement and the perlite to occur without the addition of water.
  • composition was analyzed by x-ray diffraction and x-ray fluorescence spectroscopy to determine its chemical composition.
  • X-ray diffraction revealed the presence of calcium magnesium aluminum silicate, calcium silicate, and two forms of calcium carbonate.
  • X-ray fluorescence quantitative spectroscopy revealed the following composition: Oxides Composition % (Dry Basis) silicon dioxide (Si O2) 44.94 aluminum oxide (Al2O3) 9.46 ferric oxide (Fe2O3) 1.02 calcium oxide (CaO) 34.67 magnesium oxide (MgO) 3.57 sulfur trioxide (SO3) 1.90 sodium oxide (Na2O) 0.98 potassium oxide (K2O) 1.80 titanium dioxide (TiO2) 0.27 phosphorous pentoxide (P2O5) 0.17 manganic oxide (Mn2O3) 0.03 loss on ignition 1.08 insolubles 0.11 100.00
  • the diffraction and spectroscopy test revealed that no tricalcium silicate was present and that only a small amount of dicalcium silicate was present. Significantly, dicalcium silicate and tricalcium silicate comprise between seventy and eighty percent of the composition of Portland Cement.
  • the test results further reveal a higher than expected amount (for cement) of silicon oxide, aluminum oxide, potassium oxide, and magnesium oxide, and a lower than expected amount (for cement) of calcium oxide.
  • the improved composition is mixed with water by techniques well known in the art to form the improved composite material. For example, water may be placed into a mixing chamber, and liquid additives may be blended with the water if desired. The composition is then slowly added to the water while the blender mixes the composition into the water. The composition is no longer added once the mix reaches the consistency of mastic or molasses. Next, small portions of water and composition are added until the desired amounts of water and composition are completely mixed with the water.
  • the composition can be vibrated after water is added to facilitate the formation of the improved composite material.
  • a high frequency vibrator can be used for this purpose.
  • the composition can be compressed after water is added to achieve a denser improved composite material, as is well known in the art.
  • the improved composite material can be suitably formed by adding as little as 18 pounds of water to 50 pounds of the improved composition.
  • a ratio of 18-20 pounds of water per 50 pounds of improved composition is believed to maximize the strength of the improved composite material. It is well known in the art that using excess water with cement will decrease the strength of the resulting concrete. It should be appreciated that more than 18-20 pounds of water per 50 pounds of composition may be used with a resulting loss in strength of the improved composite material.
  • the wet improved composite material can be applied by spray, by trowel, or by casting.
  • a pump that is designed specifically for the purpose of spraying viscous cementitious material should preferably be used.
  • a Moyno type pump by Strong may be used.
  • structural steel is being sprayed, the steel may be wrapped with expanded metal lath and the composition may be sprayed on the metal lath.
  • the composition can be sprayed to a thickness of one-half to three-fourths inch.
  • a trowel may be used to smooth the composition which is sprayed on expanded metal lath, and the composi­tion is then finished according to the desired surface texture.
  • FIGURE 1 illus­trates a panel 10 formed from the composition.
  • FIGURE 2 illustrates a shingle 14 formed from the composition.
  • panel 10 can be cast with a design in the face of the panel 10.
  • the composition is poured into a rectangular mold.
  • a reinforcing mat may be added to the wet improved composite material in the mold to strengthen the improved composite material.
  • the wet improved composite material is poured into one-half of the mold, formed along the plane of the mold having the greatest cross-sectional area, and suitable reinforcing wire mesh or mat is positioned in the mold on top of the composition. Additional wet improved composite material is then poured to completely fill the mold.
  • the reinforcing mat should not touch any sides of the mold.
  • the reinforcing mat should be formed to generally conform with the final configuration of the product through techniques well known in the art.
  • the size of the mesh will vary according to the size of the panel. For example, medium sized prefabricated architec­tural panels may be as large as four by ten feet in size. In other applications, the architectural panels may be larger.
  • the thickness of a panel formed from the improved composite material of the invention may vary.
  • a panel which is between one and three inches thick and is two and one-half feet square will weigh between 15 and 50 pounds.
  • the size and weight of the improved composite material products formed from the composition are not essential to the practice of the invention, but the composition permits lightweight panels to be fabricated which are easier to transport and install.
  • the improved composite material is not like known concrete or concrete derived materials. Analyses of the improved composite material have been unable to identify the presence of tricalcium silicate, which is a signifi­cant component of Portland cement. The improved composite material differs significantly from ordinary concrete because aggregate, such as gravel, is not necessary to form the material.
  • Ordinary concrete consists of a matrix of cement suspended in water that coats sand and aggregate par­ticles. The cement undergoes a chemical transformation to bind the sand and aggregate into a hard composition.
  • the improved composite material formed from the composition does not require aggregate for its strength, although aggregate of differing types can be added to vary the physical properties of the product.
  • the composition uses perlite fines having small particle sizes that combines with the cement to form the dry mixed composition. This composition when mixed with water, and allowed to dry, achieves an extremely dense, tough, monolithic durable panel or plate which has ceramic-like qualities.
  • Tests of the improved composite material show a compression strength of 3350 psi, despite the lack of aggregate in the product.
  • lightweight vermiculite-added concretes have a compressive strength ranging from 700 to 900 psi.
  • Ordinary concrete with aggregate has a compressive strength ranging from 2800-­3000 psi.
  • the tensile strength for the improved composite material is 775 to 900 psi, which is signifi­ cantly greater than the tensile strength of ordinary concrete (250-350 psi).
  • the improved composite material is beneficial in providing resistance to damage caused by fire. When the improved composite material reaches a certain temperature the cement will chemically release moisture that will cool the fire.
  • the improved composite material is superior to concrete because it has a higher resistance to thermal shock than does concrete.
  • the improved composite material panel spalled slightly on the surface, with hairline cracks appearing over the surface during a torching type test, but did not crack.
  • One explanation for the failure of the ordinary concrete panel is that the large amount of hard aggregate expands causing spalling and cracks in the panel.
  • the improved composite material does not contain large amounts of aggregate.
  • Products manufactured from the improved composite material may be easily duplicated in remote locations that are distant from manufacturing facilities.
  • the composi­tion does not use local aggregates and sand for the finished product, and this avoids deviations in the quality of the product that are due to variations in raw materials and the moisture content of the raw materials.
  • the composition is lightweight and can be easily trans­ported to remote locations, thus assuring the quality and consistency of the improved composite material.
  • the compressive strength of the improved composite material is comparable to ordinary concrete, while the flexural strength of the material is substantially higher than ordinary concrete. Accordingly, the composition can be cast in thinner panels, that are stronger and weigh less than similar panels cast from concrete. For example, an improved composite material panel ranges from 20 to 65 percent of the weight of an ordinary concrete panel of the same size.
  • the composition after mixing with water may be cast into many different forms and shapes.
  • the composition can be cast into construction components such as architectural and fascia panels, roof tiles, retaining walls, and other useful shapes. Since the composition is unaffected by water, the composition can be used in bulkheads or retaining walls subjected to or immersed in water. Moreover, the composition can be cast into struc­tural, load-bearing components. The composition may also be cast into fireproof or sound-proof panels.
  • the composition in another application, can be made into a foam by entraining a large amount of air into the composition and by other well known processes.
  • the foam resists water absorption and damage due to fire and can be cast into panels and other shapes or can be sprayed on objects through techniques which are well known in the art.
  • various fastening means may be bonded to it or may be cast into it to aid in install­ing it or building with it.
  • One unique advantage of the improved composite material is that nails, screws, and other fastening devices are easily fastened into panels or other shapes formed from the improved composite material.
  • the fastening devices can easily be removed, which furnishes a unique advantage over concrete products.
  • the invention provides a composition which can be formed into an improved composite material that is lighter, stronger, and of a more consistent quality than are products formed from known cement compositions.
  • the material was next molded into a six inch by nine inch panel that was approximately one inch thick. The panel was allowed to dry for 24 hours.
  • the resulting panel of improved composite material had a density of 80 pounds per cubic foot.
  • the compres­sive strength and Shore D hardness of the panel were 3350 psi and 75-80, respectively.
  • a panel of the improved composite material was prepared by the procedure of Example 1 using one cup of perlite powder, one cup of Portland No. I cement, and eight ounces of water.
  • the resulting panel of improved composite material had a compressive strength ranging from 1480 to 2040 psi and a Shore D hardness of 80.
  • a panel of the improved composite material was prepared by the procedure of Example 1 using one cup of perlite powder, 3 cups of Portland No. I cement, and 17 ounces of water.
  • the resulting panel of improved com­posite materials had a compressive strength ranging from 590 to 630 psi and a Shore D hardness of 47.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
EP88117510A 1987-10-23 1988-10-21 Verbundmaterial und Verfahren Expired - Lifetime EP0313055B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT88117510T ATE77615T1 (de) 1987-10-23 1988-10-21 Verbundmaterial und verfahren.

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11322987A 1987-10-23 1987-10-23
US113229 1987-10-23
US25442988A 1988-10-06 1988-10-06
US254429 1988-10-06

Publications (2)

Publication Number Publication Date
EP0313055A1 true EP0313055A1 (de) 1989-04-26
EP0313055B1 EP0313055B1 (de) 1992-06-24

Family

ID=26810825

Family Applications (1)

Application Number Title Priority Date Filing Date
EP88117510A Expired - Lifetime EP0313055B1 (de) 1987-10-23 1988-10-21 Verbundmaterial und Verfahren

Country Status (7)

Country Link
EP (1) EP0313055B1 (de)
AU (1) AU611960B2 (de)
CA (1) CA1321216C (de)
DE (1) DE3872349T2 (de)
ES (1) ES2032516T3 (de)
NO (1) NO884696L (de)
NZ (1) NZ226683A (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CZ302465B6 (cs) * 2004-03-03 2011-06-01 Moravské keramické závody, a. s. Smesi pro výrobu tepelne izolacních tvarovek z expandovaných minerálních materiálu a zpusob jejich výroby

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0431112B1 (de) * 1989-05-22 1994-08-17 Advanced Concrete Technology, Inc. Struktureller perlitbeton von hoher festigkeit

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2585366A (en) * 1948-04-20 1952-02-12 Great Lakes Carbon Corp Lightweight concrete mixture
US3565650A (en) * 1966-05-18 1971-02-23 William A Cordon Lightweight concrete products and a process of producing same
DE2549585A1 (de) * 1975-04-28 1976-11-11 Voest Ag Leichtbauplatte
DE3150701A1 (de) * 1981-12-21 1983-07-14 Hans Kramer GmbH & Co KG, 4000 Düsseldorf Verfahren zur verarbeitung einer feucht-kruemeligen, anorganischen masse aus mineralischen leichtstoffen, hydraulischen bindemitteln und wasser durch ueberfuehrung in einen fluessigen zustand und formgebendes giessen oder haftendes aufbringen auf flaechen unter erzeugung einer festen masse mit einer niedrigen rohdichte und einer in der waerme- und verbrennungstechnik ausreichenden druckfestigkeit
US4518431A (en) * 1984-08-10 1985-05-21 Duvier Jr Henry A Light weight insulating building blocks and method of making same
EP0196602A2 (de) * 1985-04-02 1986-10-08 Colfirmit Marthahütte GmbH Putz-System

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2585366A (en) * 1948-04-20 1952-02-12 Great Lakes Carbon Corp Lightweight concrete mixture
US3565650A (en) * 1966-05-18 1971-02-23 William A Cordon Lightweight concrete products and a process of producing same
DE2549585A1 (de) * 1975-04-28 1976-11-11 Voest Ag Leichtbauplatte
DE3150701A1 (de) * 1981-12-21 1983-07-14 Hans Kramer GmbH & Co KG, 4000 Düsseldorf Verfahren zur verarbeitung einer feucht-kruemeligen, anorganischen masse aus mineralischen leichtstoffen, hydraulischen bindemitteln und wasser durch ueberfuehrung in einen fluessigen zustand und formgebendes giessen oder haftendes aufbringen auf flaechen unter erzeugung einer festen masse mit einer niedrigen rohdichte und einer in der waerme- und verbrennungstechnik ausreichenden druckfestigkeit
US4518431A (en) * 1984-08-10 1985-05-21 Duvier Jr Henry A Light weight insulating building blocks and method of making same
EP0196602A2 (de) * 1985-04-02 1986-10-08 Colfirmit Marthahütte GmbH Putz-System

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CZ302465B6 (cs) * 2004-03-03 2011-06-01 Moravské keramické závody, a. s. Smesi pro výrobu tepelne izolacních tvarovek z expandovaných minerálních materiálu a zpusob jejich výroby

Also Published As

Publication number Publication date
EP0313055B1 (de) 1992-06-24
DE3872349T2 (de) 1992-12-10
NZ226683A (en) 1990-11-27
NO884696D0 (no) 1988-10-21
AU611960B2 (en) 1991-06-27
NO884696L (no) 1989-04-24
DE3872349D1 (de) 1992-07-30
AU2416888A (en) 1989-04-27
CA1321216C (en) 1993-08-10
ES2032516T3 (es) 1993-02-16

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